Metal framing member with off site manufactured layout locating tabs

ABSTRACT

A metal framing member for use as a stud, joist, rafter, truss, etc. is disclosed. The framing member includes at least one knock out opening and a corresponding tab that is positioned onto the metal framing member during the manufacturing process via computer so that structures built using the studs such as window frames, door jams, etc. are accurately and quickly fabricated. The knock out opening can also be used as a chase to allow wiring or a stiffening rod to pass through the member. Each tab is also preferably provided with a pair of pre-punched holes so that the tab can be fastened to other building components using standard screws.

[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 09/885,843, filed Jun. 20, 2001, now abandoned.

FIELD OF THE INVENTION

[0002] This invention relates to dwelling framing members, and in particular, to an attachment tab and opening which may be used a chase or to attach one stud to another in such members by having the tab and its corresponding knock out positioned onto the metal stud via computer in accordance with the layout plans of the structure that is to be formed.

BACKGROUND OF THE INVENTION

[0003] Structural members are frequently made of metal, as it is advantages over wooden structural members. Compared to wood, metal is insect proof, fire proof, and has high uniformity and strength. However, its use is limited due to high cost, erection problems, and handling difficulties. U.S. Pat. No. 5,315,804, issued to Attalla, addresses some of these concerns. The patent discloses an improved metal framing member that utilizes stiffening sections to enable lighter gauge of metal to be used. The framing member also features embossed surfaces that facilitate fastening using standard self-tapping fasteners. Safety edges are provided to eliminate the sharp edge problem of handling metal framing members.

[0004] In addition to the above concerns, a framing member often must be provided with a chase to allow wiring or other objects to pass through the member. Introducing this chase after the framing member has been fabricated, as well as clipping or attaching the wiring to the member, can be tedious and time consuming. The patent mentioned above does not address this concern.

[0005] U.S. Pat. No. 5,943,838, issued to Madsen et al. on Aug. 31, 1999, discloses the use of a bendable tab which must be bent on the job by the metal stud installer. The use of the STRONG STUD taught in the '804 patent which utilizes heavy gauge, high strength material would make accurate and effective bending by the installer costly and difficult. Further, manual bending for even heavier gauge material that might be necessary in certain construction environments would be impossible.

[0006] Further, Madsen et al. teaches the use of a tab that is substantially less than that of the opening or knock-out. However, the Madsen et al. knock-out opening is substantially greater than the size of the tab which weakens the stud and potentially can cause buckling or torsion problems. Nor does Madsen et al. disclose or suggest the use of pre-punched pilot holes but instead relies solely on the use of self-tapping screws to connect the tab to another structure.

[0007] Therefore, what is needed is an improved metal framing member that includes a manufactured locating tab that is suitable for all metal studs, irrespective of the gauge of the metal, that can be placed at predetermined positions within the stud to serve to locate the attachment of other studs, has a knock-out opening that substantially the same size as the size of the tab, has pre-formed pilot holes for simplifying the installation of standard screw fasteners, and can serve as a preformed chase and a means of clipping objects passing through the chase to the member. A metal framing member including such a chase and that is low cost and can be handled safely is not found in the prior art.

SUMMARY OF THE INVENTION

[0008] The present invention is a metal framing member including at least one manufactured locating tab. The framing member has a substantially rectangular cross-section. Preferentially, at least two stiffeners run longitudinally along the metal framing member. A tab is cut out of the bottom portion between the two stiffeners. The tab resulting from the knock out is bent substantially perpendicular to the surface which the tab is positioned thereon. The bent punch tab operates with a fastener as a clip to attach objects passing through the chase to the framing member. The tab also serves to define how the framing members are laid out to provide window locations, door locations, headers, etc. Each tab is made at the factory using computer software to accurately match each position in accordance with the building design.

[0009] Left and right rectangular side sections are substantially perpendicular to the bottom portion containing the stiffeners. The side sections have radiused edges along their top and bottom lengths. The bottom lengths join the left and right edges of the bottom section respectively. Rectangular returns are attached to each side section so that the returns are substantially perpendicular to the side sections. The returns are substantially parallel to the bottom portion.

[0010] Therefore, it is an aspect of this invention to provide an improved metal framing member.

[0011] It is another aspect of the invention to provide a framing member with a prefabricated chase.

[0012] It is a further aspect of the invention to provide a metal framing member with a means to secure objects passing through a chase to the framing member.

[0013] It is still another aspect of the invention to provide a metal framing member that has computer generated tabs to intricately mark the metal framing member to provide precise attachment points to ensure that the structure is being fabricated in accordance with design plans.

[0014] Another aspect of the invention is to provide a metal framing with at least one tab wherein the tab has a knock out area or opening that is substantially the same size and geometry of the tab.

[0015] Still another aspect of the invention is to provide a metal framing with at least one tab that provide accurate and dependable fixed locations for key elements of the design to eliminate installation errors and increase the productivity of the framing process.

[0016] These aspects of the invention are not meant to be exclusive and other features, aspects, and advantages of the present invention will be readily apparent to those of ordinary skill in the art when read in conjunction with the appended claims and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017]FIG. 1 is an isometric view with a partial cut away view of the framing member showing one manufactured layout locating tab.

[0018]FIG. 2 is a detail showing the knock out opening that can be used as a chase in the framing member.

[0019]FIG. 3 is a top view of the tab.

[0020]FIG. 4 is a cross sectional view of the framing member illustrating the stiffeners used in the preferred embodiment.

[0021]FIG. 5 is a cross sectional view of another embodiment of the framing member without the stiffeners.

[0022]FIG. 6 is still another alternative embodiment of the framing member showing a plurality of manufactured layout locating tabs.

[0023]FIG. 7 is a detailed view of one tab positioned within framing member shown in FIG. 6.

[0024]FIG. 8 is cross sectional view of the tab within the framing member shown in FIG. 6.

[0025]FIG. 9 is another embodiment of manufactured layout locating tab shown in the framing member depicted in FIG. 6.

[0026]FIG. 10 is a detailed view of the tab embodiment shown in FIG. 9.

[0027]FIG. 11 is a cross sectional view of the alternative embodiment of the tab.

[0028]FIG. 12 is front view of a typical wall that is constructed with framing members in accordance with the invention.

[0029]FIG. 13 illustrates a stiffening member that is inserted through the knock out opening of the framing member and attached to the tab provided via the knock out.

[0030]FIG. 14 shows a typical stress that may be constructed using the framing members in accordance with the invention.

[0031]FIG. 15 illustrates that manufactured layout locating tab may be positioned anywhere on the framing member including the end.

DETAILED DESCRIPTION OF THE INVENTION

[0032]FIG. 1 illustrates metal framing member 10 with knock out opening 12 and tab 14. While tab 14 is usually made so that tab 14 is approximately 90 degrees with surface 16, since tab 14 is made at the factory using computer assisted machinery, any precise angle may be selected. (See, e.g. FIG. 13) Tab 14 and its corresponding knock out opening 12 are preferably located centrally in surface 16, which runs the length of framing member 10. However, since the stud is manufactured to the design specifications necessary to ensure precision and ease of fastening, other positions can be easily be selected. In fact, different locations on surface 16 as well as different tab angles could be provided in each framing member if desired.

[0033] Surface section 16 is generally 6″ to 8″ wide. In the preferred embodiment, surface section 16 includes stiffeners 18, which run longitudinally along surface section 16. Typically, as noted above, knock out opening 12 is centrally located between stiffeners 18. Note that the geometry and size of knock out opening 12 and tab 14 are substantially the same, differing primarily due to the width of the cut. By having opening 12 and tab 14 substantially the same, less material is wasted and the framing member is stronger thus exhibiting a greater resistance to torsion forces and axis buckling.

[0034] Knock out opening 12 is shown in detail in FIG. 2. Opening 12 is cut out of surface portion 16 in an area preferably no greater than two inches by two inches. Because this opening and tab 14 are made during the time of manufacturing the framing member 10, the gauge of framing member 10 can be far thicker than would be otherwise possible if the installer had to bend tab 14 at the construction site.

[0035] In the preferred embodiment, opening 12 is 1 {fraction (11/16)}″ by 1{fraction (11/16)}″, with upper end 20 of the chase having a radius of ⅞″ instead of being cut square. Tab 14 is not completely severed from opening 12, but is connected along lower edge 22. Preferably, tab 14 is folded up at lower edge 22 so that tab 14 is substantially perpendicular to raised surface section 16. However, as noted above, other angles are easily selectable depending on the needs of the construction project.

[0036]FIG. 3 details tab 14. In addition to the primary purpose of tab 14 to provide an accurate positioning and fastening location for adjacent framing members, tab 14 can serve as a point of attachment for any objects passing through opening 12 such as wiring. Wiring or other objects may be passed from one side of the framing member to the other through opening 12 thus serving as a chase. These objects may then be fastened to tab 14 without adding additional clips.

[0037] In the preferred embodiment, two holes 24 are provided in tab 14 to serve as fastener holes. One hole 24 is positioned ½″ from lower edge 22, while the other is positioned ½″ from rounded edge 26. Holes 24 are otherwise centered on tab 14. Holes 24 preferably have a radius of {fraction (3/32)}″ and are capable of receiving standard screw fasteners (not shown) to attach wiring, stiffening rods, or other framing members to tab 14.

[0038] Returning to FIG. 1, metal framing member 10 includes left and right rectangular sections 28. Rectangular side sections 28 are preferably at least 1⅝″ in length, but may vary depending on the particular need for the framing member. Rectangular side sections 28 share an edge with surface section 16 and are substantially perpendicular to surface section 16 while being parallel to each other. At the distal ends of rectangular side sections 28 are left and right rectangular returns 30. Left and right rectangular returns 30 are preferably perpendicular to rectangular side sections 28 and parallel to bottom section 16.

[0039]FIG. 4 is a cross section of metal framing member 10, including stiffeners 18 that run the length of the member. Stiffeners 18 are ideally located on surface section 16 about 1½″to 2″ in from rectangular side sections 28, depending on the width of bottom section 16. As can be seen from FIG. 4, rectangular returns 30 do not generally extend out over stiffeners 18. It can also be seen that corners 32, formed where rectangular side sections 28 meet bottom section 16, and corners 34, formed where rectangular returns 30 meet rectangular side sections 28, may be radiused edges rather than sharp corners.

[0040]FIG. 5 is a cross section of an alternate embodiment of framing member 10. In this embodiment, bottom section 16 does not include stiffeners 18. Rather, surface section 16 is flat across its entire width other than opening 12 and tab 14.

[0041] As shown in FIG. 6-8, another alternative embodiment of the framing member 15 showing a plurality of manufactured layout locating tabs 14. Note that position of tabs 14 and the corresponding knock out openings 12 can be located anywhere along framing member. That is, it is unnecessary to use only 16 inches on center as would be required if tabs 14 and openings 12 were not made specifically to meet the requirements of each and every construction project.

[0042]FIG. 9 is another embodiment of manufactured layout locating tabs 14′ shown in the framing member depicted in FIG. 6. In this embodiment, tabs 14′ and their corresponding knock out openings 12′ are rectangular in shape. Clearly, other shapes are likewise possible such triangular, octagonal, hexagonal, etc. depending on the job requirements. Since the tabs and openings are made during the construction process of framing member, with the tab aligned at the predetermined angle relative to the web surface of framing member, a virtual infinite number of tab permutations and combinations are possible.

[0043]FIG. 12 shows a typical framed wall that using the tabs 14 to attached on framing member to the next in precise alignment. Noted that distance between the respective framing members is not always a standard (16 inches O.C.) so that the tabs (not shown) on header framing member 42 are adjusted accordingly. Also, openings and tabs can be provided so that cross bracing members 44 and 46 are accurately position therethrough thus providing a tab for attachment as well as making certain the framed wall is square. This can be seen more clearly in FIG. 13 which shows that tab 14 is positioned at an angle other 90 degrees with respect to surface portion 16.

[0044] As shown in FIG. 14, the framing member invention can even be used to construct trusses which require joining one framing member to another at varying angles and positions. The flexibility of this system is clearly illustrated in FIG. 15 which illustrates that tab 14 can be positioned at the top of framing member 10 such that one framing member 10 can be attached to another at substantially right angles.

[0045] Although the present invention has been described with reference to certain preferred embodiments thereof, other versions are readily apparent to those of ordinary skill in the art. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred embodiments contained herein. 

What is claimed is:
 1. An off site manufactured metal framing member comprising: a rectangular section having left and right substantially parallel edges along the length of said section, said section also having top and bottom surfaces; at least one knock out opening having a lower edge, left and right side edges, and an upper radiused edge with said edges together define a opening profile, said opening profile disposed in said rectangular section and allowing passage to and from said top surface and said bottom surface of said bottom section; and at least one tab corresponding to said at least one knock out opening and disposed at said lower edge of said opening profile, said tab also having left and right side edges and having an upper radiused edge with said edges taken together define a tab profile such that said tab profile and said opening profile are substantially the same; said at least one tab positioned at predetermined angle with respect to rectangular section; said tab also having at least one pair of pre-punched pilot holes such that standard screw fasteners made be utilized to fastening a structure to said at least one tab; and wherein said structure may be passed through said at least one opening profile such that are passed through said framing member by way of said opening profile.
 2. The off site manufactured metal framing member of claim 1 wherein said at least one knock out opening and said corresponding at least one tab are positioned during the manufacturing process by a computer in accordance with a predetermined layout plan such that the configuration and position of said at least one knock out opening and said corresponding at least one tab serve to precisely locate any other structural member that is to be attached to said framing member.
 3. The metal framing member of claim 1 further comprising a plurality of knock out openings with each knock out opening have a corresponding tab with each opening tab pair wherein at least one opening tab pair is located at different distance along said metal framing member than another opening tab pair.
 4. The metal framing member of claim 1 wherein the predetermined angle of at least one tab is substantially different than 90 degrees.
 5. The metal framing member of claim 1 wherein the predetermined angle of at least one tab is approximately 90 degrees.
 6. An off site manufactured metal framing member comprising: a pair of opposed flanges; and a central web portion disposed between said pair of opposed flanges; said central web portion having at least one knock out opening; and said central web portion having at least one tab that corresponds to said knock out opening wherein said at least one knock out opening and its corresponding said at least one tab are cut into said central web portion such that said at least one knock out opening and its corresponding said at least one tab are hinged together at a common edge and are positioned onto said central web portion during the manufacturing process of constructing said metal framing member; and wherein said tab is angled at a predetermined angle relative to said central web portion and wherein said at least one tab and its corresponding said at least one knock out opening and its corresponding said at least one tab are approximately the same size and approximately the same peripheral shape.
 7. The off site manufactured metal framing member of claim 6 where each of said tabs further comprises at least one pair of pre-punched pilot holes such that standard screw fasteners made be utilized to fastening a structure to said tab
 8. The off site manufactured metal framing member of claim 6 wherein the position of said at least one knock out opening and its corresponding said at least one tab is accomplished by a computer that places said position in accordance with structural layout for which said metal framing member is to be used.
 9. The off site manufactured metal framing member of claim 6 where the peripheral shape of at least one said tab and its corresponding at least one knock out opening is rectangular.
 10. The off site manufactured metal framing member of claim 7 where the peripheral shape of at least one said tab and its corresponding at least one knock out opening is rectangular and has an curved edge opposite to said hinged edge wherein said curved edge has an predetermined radiused arc. 